Pvc Pipe manufacturing its procedure , cost & application

Pvc Pipe manufacturing its procedure , cost & application by Engr. umair raza

1. PVC PIPE Manufacturing Mechanical Gladiators

2. Engr. Umair Raza 19013386-002

3. PVC Pipes Engr. Umair Raza

4. PVC Pipe Making Machine Engr. Umair Raza

5. PVC Pipe Making Machine Parts Engr. Umair Raza

6. PVC Pipe Making Machine Parts Engr. Umair Raza

7. What Is PVC?   Polyvinyl chloride , more correctly but unusually poly(vinyl chloride), commonly abbreviated PVC, is the world's third-most widely produced synthetic plastic polymer, after polyethylene and polypropylene. Engr. Umair Raza

8. What Is PVC? PVC comes in two basic forms: rigid (sometimes abbreviated as RPVC) and flexible. The rigid form of PVC is used in construction for pipe and in profile applications such as doors and windows. It is also used for bottles, other non-food packaging, and cards (such as bank or membership cards). It can be made softer and more flexible by the addition of plasticizers, the most widely used being phthalates. In this form, it is also used in plumbing, electrical cable insulation, imitation leather, signage, phonograph records, inflatable products, and many applications where it replaces rubber. Pure poly(vinyl chloride) is a white, brittle solid. It is insoluble in alcohol but slightly soluble in tetrahydrofuran. Engr. Umair Raza

9. PVC Compound Formulation Engr. Umair Raza

10. Discover The PVC PVC was accidentally synthesized in 1872 by German chemist Eugen Baumann. The polymer appeared as a white solid inside a flask of vinyl chloride that had been left exposed to sunlight. In the early 20th century the Russian chemist Ivan Ostromislensky and Fritz Klatte of the German chemical company Griesheim- Elektron both attempted to use PVC in commercial products, but difficulties in processing the rigid, sometimes brittle polymer thwarted their efforts. Waldo Semon and the B.F. Goodrich Company developed a method in 1926 to plasticize PVC by blending it with various additives. The result was a more flexible and more easily processed material that soon achieved widespread commercial use.  Engr. Umair Raza

11. Raw Materials i ) PVC Resin 100 100 ii) Stabilizer (Non toxic) 5 iii) Primary Plasticizer 1.5 iv) Secondary Plasticizer 5 v) Internal Lubricant 3 vi) External Lubricant 4 vii) Epoxy Plasticizer 1.5 viii) Pigment base 3 ix) Pigment As Required Engr. Umair Raza

12. Why do we use PVC pipes for water supply instead of metal pipes? There are several reasons for this. Firstly PVC is much lighter, stronger and can be made in much longer lengths. If PVC is compressed it simply distorts slightly and if the compression relaxes it will go back to its original shape. Metal once compressed keeps that shape and can cause weakness in the metal walls and possibly crack causing leakage . Also water and oxygen cause ferrous metals to oxidize which creates rust on both the inside and outside of the pipes and eventually weakening it . Build up of rust in the pipework will also restrict flow of water increasing the pressure on the walls of the pipe and reduced flow to the customer. In the case of ground movement PVC simply bends according to the ground it is laid in where as metal does not and if soil beneath it sinks eventually the pressure on the top will distort the pipe permanently again restricting flow . PVC Also prevents any form of contamination being added to the water passing through It . Although the leach of iron is not harmful to humans , many smaller pipes were once made of lead and small amounts did get added to the water , this over time builds up in the body as it does not get excreted like excess iron does and can cause severe damage to the brain and kidneys . Engr. Umair Raza

13. Processing Extrusion. Plasticizers. Stabilizers. Lubricants. Fillers. Sizing. Traction. Cutting   Engr. Umair Raza

14. Processing The basic material which on Polymerization produces P.V.C. Pipes is Poly vinyl chloride which in resin form is hard and rigid. The rigidity can be controlled by controlling the percentage of plasticizer at the time of compounding. Production of Rigid PVC pipe is based on plasticizing and homogenizing PVC compound and then passing the compound through an extruder. The hot molten PVC compound is extruded through a circular slit. Circular slit governs the size of pipe to be extruded. Different dies are used for manufacturing different size of pipes. The Pipes thus extruded through the die is then passed through a vacuum sizing tank wherein the dimensions of the pipe can be accurately set. It also helps in surface finish of the pipes. Vacuum sizing reduces the percentage of wastage considerably . Engr. Umair Raza

15. Processing As the pipe being extruded is rigid in form they cannot be wound into coils. So an inline motorized cutting device should be provided for cutting the pipes into required sizes. For ascertaining the consistency in product quality the unit should be equipped with process control laboratory for preliminary testing of raw materials. The unit may also have arrangement for quality testing of finished products. Engr. Umair Raza

16. Processing Extrusion: PVC uncompounded resin, unlike some other thermoplastics is not suitable for direct processing. To confer the required processing and end instability, it is necessary to mix additives to the PVC resin. Following are some of the additives which are generally used for the manufacture of rigid PVC pipes. Plasticizers : The common plasticizer in use are DOP, DIOP, DBP, DOA, DEP, Reoplast , Perplex etc . Engr. Umair Raza

17. Processing Stabilizers: The common stabilizers are lead, barium, cadmium, tib , stearate etc. Lubricants: Widely used lubricants are Buty -Stearate, Glycerol Moni- Stearate, Epoxidised Monoester of oleic acid, stearic acid etc . Fillers : Fillers are also used for producing special quality product (e.g. calcined clay is used to improve the electrical properties of cable compounds). Before the extrusion operation PVC resin is to be compounded with plasticizers, stabilizers, lubricants and fillers to improve processibility and improve the endure stability. PVC resin is compounded with other ingredients in a high speed mixer. The compound resin is fed to the double screw extruder where the inserts and die body for the required pipe diameter are fitted. The PVC compounds are then passed through a heated chamber and they get melted under the compression of the screw and temperature of the barrel. The marking on the pipe is done at the time of extrusion . Engr. Umair Raza

18. Processing Sizing: The pipes coming out from the extruder is cooled in the sizing operation. There are basically two types of sizing used for manufacturing of pipes. ( i ) Pressure sizing & (ii) Vacuum sizing. Traction: The next operation needed after sizing is traction. The tube traction unit is required for continuous haulage of the pipes being extruded by the extruder. Cutting: The last operation needed is cutting. There are basically two cutting techniques for rigid PVC pipes viz. manual and auto matic . The pipes are then tented for ISI marks and are ready for dispatching. 17 Engr. Umair Raza

19. Environmental Impact Polyvinyl Chloride, more commonly known as PVC or just vinyl, has been in widespread usage since the early-mid 20th century . PVC is strong, resistant to oil and chemicals, sunlight, weathering and flame resistant. It’s everywhere around us. PVC is an incredibly versatile material use in bottles, packaging, toys, construction materials, bedding, clothing, piping, wire coatings, imitation leather, furnishings and more. PVC ranks the third in both global plastic output and consumption. Over 33 million tons of PVC is being produced each year and that figure is increasing annually. Around 57% of PVC’s mass is chlorine, so it requires less petroleum than many other polymers. Engr. Umair Raza

20. Demand In Pakistan PVC demand for the year could grow from around 100,000 tonnes / year to 120,000-125,000 tonnes /year as a result, they added. ... Demand this year has exceeded initial expectations so far,” said a source close to Engro Polymer and Chemicals, the sole chlor -alkali producer in Pakistan. Engr. Umair Raza

21. Thermal & Fire Properties of PVC The heat stability of raw PVC is very poor, so the addition of a heat stabilizer during the process is necessary in order to ensure the product's properties. PVC starts to decompose when the temperature reaches 140 °C (284 °F), with melting temperature starting around 160 °C (320 °F). The linear expansion coefficient of rigid PVC is small and has good flame retardancy , the Limiting oxygen index (LOI) being up to 45 or more. The LOI is the minimum concentration of oxygen, expressed as a percentage, that will support combustion of a polymer and noting that air has 20% content of oxygen. Engr. Umair Raza

22. Electrical properties of PVC   PVC is a polymer with good insulation properties, but because of its higher polar nature the electrical insulating property is inferior to non polar polymers such as polyethylene and polypropylene. Since the dielectric constant, dielectric loss tangent value, and volume resistivity are high, the corona resistance is not very good, and it is generally suitable for medium or low voltage and low frequency insulation materials. Engr. Umair Raza

23. Chemical Properties   PVC is chemically resistant to acids, salts, bases, fats, and alcohols; therefore, it is used in sewerage piping. It is also resistant to some solvents, mainly uPVC. Plasticized PVC, also known as PVC-P , is in some cases less resistant to solvents. For example, PVC is resistant to fuel and some paint thinner. Some solvents may only swell it or deform it but not dissolve it, but some of them, like tetrahydrofuran or acetone, may damage it. Engr. Umair Raza

24. Application of PVC Economical, versatile polyvinyl chloride (PVC, or vinyl) is used in a variety of applications in the building and construction, health care, electronics, automobile and other sectors, in products ranging from piping and siding, blood bags and tubing, to wire and cable insulation, windshield system components and more. Engr. Umair Raza

25. Applications Of PVC Building and Construction. Siding and Windows Wiring and Cables Water Pipes Packaging Healthcare Household Products Engr. Umair Raza

26. Applications Explanation Of PVC Building and Construction: About three-quarters of all vinyl produced goes into long-lasting building and construction applications. Life-cycle studies  show PVC/vinyl is effective in protecting the environment, in terms of low greenhouse gas emissions and conservation of resources and energy. Because it is strong and resistant to moisture and abrasion, vinyl is ideal for cladding, windows, roofing, fencing, decking, wallcoverings, and flooring. Vinyl does not corrode like some building materials, does not require frequent painting and can be cleaned with mild cleaning products. Siding and Windows Vinyl helps produce siding and window frames that are extremely durable, affordable, and help conserve energy when heating and cooling homes. In fact, vinyl windows have three times the heat insulation of aluminum windows. Engr. Umair Raza

27. Applications Explanation Of PVC Wiring and Cables: Vinyl is able to withstand tough conditions behind building walls – such as exposure to changing temperatures and dampness – for the life of the building. As a result, it is one of the most prevalent and trusted materials used in electrical wiring and cables. Water Pipes PVC helps conserve energy and water by creating virtually leak-free pipes that are not prone to corrosion and resist environmental stress. PVC breakage rates are as low as one percent of the breakage rates of cast metal systems. The lack of build-up in PVC piping improves functionality and increases energy efficiency . Household Products: PVC’s affordability, durability and water resistance make it ideal for rain coats, boots and shower curtains Engr. Umair Raza

28. Applications Explanation Of PVC Packaging: Because it is durable, dependable and light weight, flexible PVC helps packaging do its job to maintain the integrity of the products inside, including medicines. Clear vinyl is used in tamper-resistant over-the-counter medications and shrink wrap for consumer products. Rigid vinyl film is used in blister and clamshell packaging to protect medicines, personal care products and other household goods. Healthcare: Vinyl plays a critical safety role in dispensing life-saving medicine through IV bags and medical tubing. The advent of the PVC blood-collection bag was a significant breakthrough because blood bags are flexible and unbreakable, enhancing the development of ambulatory medicine and serving as the foundation for modern blood banks. Engr. Umair Raza

29. Advantages OF PVC Processed by thermoplastic methods. Wide range of flexibility possible with varying levels of plasticizer. Plastisol processing possible. Non-flammable. Dimensional stability. Comparatively low cost. Good resistance to weathering Engr. Umair Raza

30. Disadvantages OF PVC Attacked by several solvent types . Limited thermal capability. Thermal decomposition evolves HCI. Stained by Sulphur compounds. Higher density than other plastics. Engr. Umair Raza

31. Why we use PVC pipe? PVC pipes have clear environmental advantages over traditional materials. As  PVC  is a low carbon plastic,  PVC pipes require less energy and fewer resources to manufacture. Due to their low weight, less energy is used when transported.  PVC pipes last long with a minimum of maintenance and they are easily recyclable . PVC's abrasion resistance, light weight, good mechanical strength and toughness are key technical advantages for its use in building and construction applications. PVC can be cut, shaped, welded and joined easily in a variety of styles. Its light weight reduces manual handling difficulties. Engr. Umair Raza

32. Benefits Of PVC Pipe Polyvinyl chloride, PVC, is one of the most popular plastics used in building and construction. It is used in drinking water and waste water pipes, window frames, flooring and roofing foils, wall coverings, cables and many other applications as it provides a modern alternative to traditional materials such as wood, metal, rubber and glass. These products are often lighter , less expensive and offer many performance advantages Strong and lightweight Easy to install Durable Cost-effective Safe material (PVC is non-toxic) Fire resistant Good insulator Versatile Engr. Umair Raza

33. Problem Of PVC   For starters, oil and chlorine aren’t what you’d call “green” substances in regards to their extraction, refining and by- products. So much of our modern life is based on oil that if production were to suddenly increase, it’s not just transport that would suffer , it would affect every aspect of our lives. We really need to kick our fossil fuel addiction before we are forced into withdrawals. • PVC’s durability is also its downfall environmentally speaking , it’s not biodegradable or degradable. Items made from PVC will retain their form for decades and the breakdown that occurs is just granulation , the pieces simply become smaller. Animals can ingest these pieces and the plastic can block their digestive tracts. Engr. Umair Raza

34. Alternative To PVC  This is a tough one. Some new materials with most of the desirable properties of PVC, without the health and environmental concerns are now being produced. These degradable plastics are engineered to breakdown under landfill conditions (darkness, heat and moisture) within a few years without emitting toxic gases or other pollutants. At this point in time, these sorts of materials aren’t widely available and are quite expensive . However, the more environmentally friendly materials that PVC originally replaced are still around. These are economical and widely available. For a list of PVC alternatives, check out this article on Greenpeace’s site PVC Solutions. Engr. Umair Raza

35. Recommendations By this feasibility study we can understand that The project is socially economically and technically viable and can be taken up for implementation. Engr. Umair Raza